2002 YAMAHA YZF-R6 oil level

INSTRUMENT AND CONTROL FUNCTIONS
3-3
3
EAU04222
Oil level/coolant temperature warn-
ing light “”
This warning light has the following
three functions.

When the engine oil level is low,
the warning light comes on and
symbol “” flashes. If this oc-
curs, stop the engine immediately
and add engine oil to the specified
level.


When the coolant temperature is
too high, the warning light comes
on and symbol “” flashes. Stop
the motorcycle and allow it to idle
until the coolant temperature goes
down. If the temperature does not
go down, stop the engine. (See
the “Engine overheating” section
on page 6-45 for further instruc-
tions.)


When the engine oil level is low
and the coolant temperature is too
high, the warning light flashes and
symbols “” and “” come on.
To check that the warning light is work-
ing properly:


Put the transmission in neutral or
apply the clutch lever.


Turn the engine stop switch to
“” and the key to “ON”.


The warning light will come on,
and symbols “” and “” will
appear in the display.
If the warning light does not come on,
have a Yamaha dealer inspect the
electrical circuit.
EC000118
CAUTION:_

Do not operate the motorcycle
until you know that the engine
oil level is sufficient.


Do not operate the engine if it is
overheated.
_NOTE:_ Even if the oil is filled to the specified
level, the warning light may flicker
when riding on a slope or during sud-
den acceleration or deceleration, but
this is normal. _
1. Oil level symbol “”
2. Oil level/coolant temperature
warning light “”
3. Coolant temperature symbol “”U5MTE1.book Page 3 Monday, August 6, 2001 6:10 PM

4-1
4
EAU01114
4-PRE-OPERATION CHECKSThe condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly,
even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss
of tire air pressure could have serious consequences. Therefore, it is very important, in addition to a thorough visual inspec-
tion, to check the following points before each ride.
EAU03439
Pre-operation check list
CO-01E
ITEM CHECKS PAGE
Fuel•Check fuel level in fuel tank.
•Refuel if necessary.
•Check fuel line for leakage.3-11–3-12
Engine oil•Check oil level in engine.
•If necessary, add recommended oil to specified level.
•Check vehicle for oil leakage.6-9–6-10
Coolant•Check coolant level in reservoir.
•If necessary, add recommended coolant to specified level.
•Check cooling system for leakage.6-13–6-14
Front brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.6-27–6-29
Rear brake•Check operation.
•If soft or spongy, have Yamaha dealer bleed hydraulic system.
•Check fluid level in reservoir.
•If necessary, add recommended brake fluid to specified level.
•Check hydraulic system for leakage.6-26–6-29
Clutch•Check operation.
•Lubricate cable if necessary.
•Check lever free play.
•Adjust if necessary.6-25
Throttle grip•Make sure that operation is smooth.
•Check free play.
•If necessary, have Yamaha dealer make adjustment or lubricate.6-21
U5MTE1.book Page 1 Monday, August 6, 2001 6:10 PM

5-1
5
EAU00372
5-OPERATION AND IMPORTANT RIDING POINTS
EAU00373
WARNING
@

Become thoroughly familiar
with all operating controls and
their functions before riding.
Consult a Yamaha dealer re-
garding any control or function
that you do not thoroughly un-
derstand.


Never start the engine or oper-
ate it in a closed area for any
length of time. Exhaust fumes
are poisonous, and inhaling
them can cause loss of con-
sciousness and death within a
short time. Always make sure
that there is adequate
ventilation.


Before starting out, make sure
that the sidestand is up. If the
sidestand is not raised com-
pletely, it could contact the
ground and distract the opera-
tor, resulting in a possible loss
of control.
@
EAU01382*
Starting a cold engine In order for the ignition circuit cut-off
system to enable starting, one of the
following conditions must be met:

The transmission is in the neutral
position.


The transmission is in gear with
the clutch lever pulled and the
sidestand up.
EW000054
WARNING
@

Before starting the engine,
check the function of the igni-
tion circuit cut-off system ac-
cording to the procedure
described on page 3-25.


Never ride with the sidestand
down.
@1. Turn the key to “ON” and make
sure that the engine stop switch is
set to “”.
ECA00005
CAUTION:@ The oil level/coolant temperature
warning light and fuel level warning
light should come on for a few sec-
onds, then go off. If a warning light
does not go off, see page 3-4 for the
corresponding warning light circuit
check. @2. Shift the transmission into the neu-
tral position.NOTE:@ When the transmission is in the neutral
position, the neutral indicator light
should be on, otherwise have a
Yamaha dealer check the electrical
circuit. @3. Turn the starter (choke) on and
completely close the throttle. (See
page 3-13 for starter (choke)
operation.)
4. Start the engine by pushing the
start switch.
U5MTE1.book Page 1 Monday, August 6, 2001 6:10 PM

6
PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit .................................................... 6-1
Periodic maintenance and lubrication chart ......... 6-3
Removing and installing the cowlings and
panel .................................................................. 6-6
Checking the spark plugs .................................... 6-8
Engine oil and oil filter cartridge .......................... 6-9
Coolant .............................................................. 6-13
Checking the air filter element ........................... 6-17
Air intake duct .................................................... 6-19
Adjusting the carburetors ................................... 6-20
Adjusting the engine idling speed ...................... 6-20
Adjusting the throttle cable free play .................. 6-21
Adjusting the valve clearance ............................ 6-21
Tires ................................................................... 6-21
Cast wheels ....................................................... 6-24
Adjusting the clutch lever free play .................... 6-25
Adjusting the brake pedal position ..................... 6-26
Adjusting the rear brake light switch .................. 6-26
Checking the front and rear brake pads ............. 6-27
Checking the brake fluid level ............................ 6-28
Changing the brake fluid .................................... 6-29
Drive chain slack ................................................ 6-29Lubricating the drive chain ................................ 6-31
Checking and lubricating the cables ................. 6-31
Checking and lubricating the throttle grip and
cable ............................................................... 6-32
Checking and lubricating the brake and
clutch levers .................................................... 6-32
Lubricating the brake pedal ............................... 6-32
Checking and lubricating the sidestand ............ 6-33
Lubricating the rear suspension ........................ 6-33
Checking the front fork ...................................... 6-33
Checking the steering ....................................... 6-34
Checking the wheel bearings ............................ 6-35
Battery ............................................................... 6-35
Replacing the fuses .......................................... 6-37
Replacing a headlight bulb ................................ 6-38
Tail/brake light ................................................... 6-39
Replacing a turn signal light bulb ...................... 6-39
Supporting the motorcycle ................................ 6-39
Front wheel ....................................................... 6-40
Rear wheel ........................................................ 6-41
Troubleshooting ................................................. 6-43
Troubleshooting charts ...................................... 6-44
U5MTE1.book Page 1 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
10
*Wheels•Check runout and for damage.√√√√
11*Tires•Check tread depth and for damage.
•Replace if necessary.
•Check air pressure.
•Correct if necessary.√√√√ √
12*Wheel bearings•Check bearing for looseness or damage.√√√√
13*Swingarm•Check operation and for excessive play.√√√√
•Lubricate with lithium-soap-based grease. Every 50,000 km
14 Drive chain•Check chain slack.
•Make sure that the rear wheel is properly aligned.
•Clean and lubricate.Every 1,000 km and after washing
the motorcycle or riding in the rain
15*Steering bearings•Check bearing play and steering for roughness.√√√√√
•Lubricate with lithium-soap-based grease. Every 20,000 km
16*Chassis fasteners•Make sure that all nuts, bolts and screws are properly tightened.√√√√ √
17 Sidestand•Check operation.
•Lubricate.√√√√ √
18*Sidestand switch•Check operation.√√√√√ √
19*Front fork•Check operation and for oil leakage.√√√√
20*Shock absorber
assembly•Check operation and shock absorber for oil leakage.√√√√
21*Rear suspension relay
arm and connecting arm
pivoting points•Check operation.√√√√
•Lubricate with lithium-soap-based grease.√√
22*Carburetors•Check starter (choke) operation.
•Adjust engine idling speed and synchronization.√√√√√ √
23 Engine oil•Change.
•Check oil level and vehicle for oil leakage.√√√√√ √
24 Engine oil filter cartridge•Replace.√√√ NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (×1,000 km)
ANNUAL
CHECK
1 10203040
U5MTE1.book Page 4 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-9
6Before installing a spark plug, the spark
plug gap should be measured with a
wire thickness gauge and, if necessary,
adjusted to specification.
Clean the surface of the spark plug
gasket and its mating surface, and then
wipe off any grime from the spark plug
threads.
NOTE:
@
If a torque wrench is not available when
installing a spark plug, a good estimate
of the correct torque is 1/4–1/2 turn
past finger tight. However, the spark
plug should be tightened to the speci-
fied torque as soon as possible. @
ECA00021
CAUTION:@ Do not use any tools to remove or
install the spark plug cap, otherwise
the ignition coil coupler may get
damaged. The spark plug cap may
be difficult to remove because the
rubber seal on the end of the cap fits
tightly. To remove the spark plug
cap, simply twist it back and forth
while pulling it out; to install it, twist
it back and forth while pushing it in. @
EAU04224
Engine oil and oil filter
cartridge The engine oil level should be checked
before each ride. In addition, the oil
must be changed and the oil filter car-
tridge replaced at the intervals speci-
fied in the periodic maintenance and
lubrication chart.
To check the engine oil level
1. Place the motorcycle on a level
surface and hold it in an upright
position.NOTE:_ Make sure that the motorcycle is posi-
tioned straight up when checking the oil
level. A slight tilt to the side can result in
a false reading. _
a. Spark plug gapSpark plug gap:
0.6–0.7 mm
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf)
U5MTE1.book Page 9 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-10
6 2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Wait a few minutes until the oil set-
tles, remove the oil filler cap, wipe
the dipstick clean, insert it back
into the oil filler hole (without
screwing it in), and then remove it
again to check the oil level.
NOTE:_ The engine oil should be between the
minimum and maximum level marks. _4. If the engine oil is below the mini-
mum level mark, add sufficient oil
of the recommended type to raise
it to the correct level.
5. Insert the dipstick into the oil filler
hole, and then tighten the oil filler
cap.To change the engine oil (with or
without oil filter cartridge replace-
ment)
1. Remove cowlings A and B. (See
page 6-6 for cowling removal and
installation procedures.)
2. Start the engine, warm it up for
several minutes, and then turn it
off.
3. Place an oil pan under the engine
to collect the used oil.
1. Engine oil filler capRight side
1. Maximum level mark
2. Minimum level mark
U5MTE1.book Page 10 Monday, August 6, 2001 6:10 PM

PERIODIC MAINTENANCE AND MINOR REPAIR
6-12
6 7. Install the new oil filter cartridge
with an oil filter wrench, and then
tighten it to the specified torque
with a torque wrench.
8. Install the engine oil drain bolt, and
then tighten it to the specified
torque.9. Add the specified amount of the
recommended engine oil, and
then install and tighten the oil filler
cap.
ECA00105
CAUTION:_

In order to prevent clutch slip-
page (since the engine oil also
lubricates the clutch), do not
mix any chemical additives with
the oil or use oils of grade “CD”
or higher. In addition, do not
use oils labeled “ENERGY CON-
SERVING II” or higher.


Make sure that no foreign mate-
rial enters the crankcase.
_10. Start the engine, and then let it idle
for several minutes while checking
it for oil leakage. If oil is leaking,
immediately turn the engine off
and check for the cause.NOTE:_ After the engine is started, the engine
oil level warning light should go off if the
oil level is sufficient. _
EC000067
CAUTION:_ If the oil level warning light flickers
or remains on, immediately turn the
engine off and have a Yamaha deal-
er check the vehicle. _11. Turn the engine off, and then
check the oil level and correct it if
necessary.
12. Install the cowlings.
1. Torque wrench
Tightening torque:
Oil filter cartridge:
17 Nm (1.7 m·kgf)
Tightening torque:
Engine oil drain bolt:
43 Nm (4.3 m·kgf)Left side
Recommended engine oil:
See page 8-1.
Oil quantity:
Without oil filter cartridge
replacement:
2.5 L
With oil filter cartridge
replacement:
2.7 L
Total amount (dry engine):
3.5 L
U5MTE1.book Page 12 Monday, August 6, 2001 6:10 PM